Abstract: A method for creating a fan cowl with a hollow hat stiffener includes pressing a resin film between a non-crimp fabric (NCF) and a release poly-film to create a resin-fabric sheet. The method further includes cutting the resin-fabric sheet to a pre-determined shape to create at least one of a first resin-fabric preform, a second resin-fabric preform, and a third resin-fabric preform, draping at least the first resin-fabric preform over a tool to create an outer layer of the fan cowl, setting a mandrel over the outer layer, and draping the second resin-fabric preform over at least a portion of the mandrel and at least a portion of the first resin-fabric preform to form the hollow hat stiffener having a geometry similar to a shape of the mandrel.

Abstract: A method for creating a fan cowl with a hollow hat stiffener includes pressing a resin film between a non-crimp fabric (NCF) and a release poly-film to create a resin-fabric sheet. The method further includes cutting the resin-fabric sheet to a pre-determined shape to create at least one of a first resin-fabric preform, a second resin-fabric preform, and a third resin-fabric preform, draping at least the first resin-fabric preform over a tool to create an outer layer of the fan cowl, setting a mandrel over the outer layer, and draping the second resin-fabric preform over at least a portion of the mandrel and at least a portion of the first resin-fabric preform to form the hollow hat stiffener having a geometry similar to a shape of the mandrel.

Abstract: A method may include placing a dry fabric over a tool; pressing a first resin film over the dry fabric while the dry fabric is draped over the tool to create an outer layer of the laminate composite structural component; repeating the placing and pressing process until a desired thickness of the outer layer is achieved; compressing a second resin film and a dry fiber fabric between two rollers to tack the second resin film to the dry fiber fabric to create a resin-fabric sheet comprising a resin film layer and an dry fiber fabric layer; cutting the resin-fabric sheet to a pre-determined shape to create at least one resin-fabric preform; and draping a first resin-fabric preform over at least a portion of the outer layer, wherein one or more edges of the first resin-fabric preform overlap the outer layer to create an internal edge.

Abstract: A method may include placing a dry fabric over a tool; pressing a first resin film over the dry fabric while the dry fabric is draped over the tool to create an outer layer of the laminate composite structural component; repeating the placing and pressing process until a desired thickness of the outer layer is achieved; compressing a second resin film and a dry fiber fabric between two rollers to tack the second resin film to the dry fiber fabric to create a resin-fabric sheet comprising a resin film layer and an dry fiber fabric layer; cutting the resin-fabric sheet to a pre-determined shape to create at least one resin-fabric preform; and draping a first resin-fabric preform over at least a portion of the outer layer, wherein one or more edges of the first resin-fabric preform overlap the outer layer to create an internal edge.